OK, I looked at your pictures on the linked post and what I would do to fix this is simply applique the center part of the sun on instead of peicing it. You can modify the size of it any way you want then. I would take your ray units without the arched unit that is puckering up on you and complete the blocks as rays. Then I would draft your enlongated arch as one solid piece and applique it in place right over the "hole" left from the arch unit you can't get to piece correctly. Many mariner's compass are assembled this way. I hope I am not too late, this is too beautiful to throw away. Put it to the side for a few months and try doing it via applique. With applique you can draft you the arc piece to be whatever size you need it to be.